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Raypak 240692 - page 1
ELECTRONIC BOILER SEQUENCER & OUTDOOR RESET CONTROLLER Inst allation and Operating Instructions Catalog No: 5000.54H Effective: 06-19-07 Replaces: 02-01-04 PN 240692 Rev . 9 ...
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Raypak 240692 - page 2
Y–SERIES ELECTRONIC BOILER CONTROL Installation and Operating Instructions is a registered trademark of Underwriters Laboratories Inc.® is a registered trademark of Underwriters Laboratories-Canada Inc. ® Before operating this product, please read these instructions completely . 2 ...
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Raypak 240692 - page 3
T ABLE OF CONTENTS Contents Page Basics 4 Important Safety Instructions 4 Intr oduction 5 Concept of Operation 5 Optional Configurations 5 Control Featur e s 6 Installation and Mounting 7 Mechanical Installation 7 Electrical Installation 7 Wiring: Power to Controller 8 Air T emperature Sensor 9 W ater T emperature Sensor Installation 10 Hydronic In ...
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Raypak 240692 - page 4
BASICS Contents Item Quantity Y–Series Boiler Control, Installed on Boiler(s) As Ordered Outdoor T emperature Sensor Assembly 1 W ater T emperature Sensor Assembly 1 Optional Equipment As Ordered Check packaging for damaged or missing components. IMPOR T ANT SAFETY INSTRUCTIONS IMPOR T ANT NOTICE: These instructions are intended for use by qualif ...
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Raypak 240692 - page 5
Thank you for selecting the Raypak Y–Series Electronic Boiler Control. It is our sincere hope that you will enjoy its outstanding design, ease of use and energy saving features. INTRODUCTION The Y -Series Electronic Boiler Control (controller) is a microprocessor -based energy management system designed to control either single or multiple stage- ...
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Raypak 240692 - page 6
CONTROL FEA TURES The Y -Series sequence panel includes: • S tandard Indicator Lights: Stages 1 to 8: Red, indicates which stages are turned on. Pump: Green, indicates that the pump circuit is energized. Call for Heat: Green, indicates that a call for heat signal is present. Control On: Green, indicates outdoor temperature is below the Outdoor Cu ...
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Raypak 240692 - page 7
7 INST ALLA TION AND MOUNTING If the Y–Series Electronic Boiler Control was not mounted on the boiler by the factory , care should be taken to select a suitable mounting location. The control should be mounted on a solid and permanent base. The control enclosure is NEMA 3R rated, rainproof and sleet resistant, and can be mounted outdoors if requi ...
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Raypak 240692 - page 8
CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C VOL T -OHM METER CHECK YOUR POWER SOURCE Using a volt-ohm meter , check the following voltages at the circuit breaker panel: AC = 108 V olts AC Minimum, 132 V olts MAX AB = 108 V olts AC Minimum, 132 V olts MAX BC = Must be less than 1.0 V olts AC WIRING: POWER SOURCE T O CONTROLLER • Observe polarity ...
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Raypak 240692 - page 9
AIR TEMPERA TURE SENSOR Fig. #9040 OUTDOOR AIR TEMPERA TURE SENSOR Outdoor Air T emperature Sensor Installation Notes: • Locate the sensor on the coldest side of building, usually the North or W est side. • Install the sensor in a shaded area, out of direct sunlight. • Locate no higher than 2/3 up the side of the building, or between the 2nd ...
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Raypak 240692 - page 10
W A TER TEMPERA TURE SENSOR INST ALLA TION HYDRONIC INST ALLA TIONS Fig. #9496 TYPICAL W A TER SENSOR • The water sensor should be installed in the system supply . • Locate the water temperature sensor in the system piping just prior to the first boiler connections, on the upstream side of the System Supply Loop. • Cable length must not excee ...
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Raypak 240692 - page 11
Air temperature sensor must be installed across air temperature sensor contacts. The sensor is not activated and can be left stored in controller enclosure. 11 DOMESTIC HOT W A TER APPLICA TION SETUP PROCEDURE 1 . Install a 10,000 Ohm, 1/8 W att resistor between pins 1 and 2 on P2 connector (see pg. 13), in place of the Outdoor Air T emperature Sen ...
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Raypak 240692 - page 12
12 1 . Install the air temperature sensor across the air temperature sensor contacts (P2, pins 1 and 2; see the field wiring diagram on pg. 13). 2 . On the mode selector switch (S3), set switch #2 (Outdoor Reset) to ON to disable the outdoor reset function. (See pg.s 15 and 23). 3 . Set the Outdoor Cutoff T emperature to 200°F . (See pg. 21.) 4 . ...
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Raypak 240692 - page 13
FIELD WIRING Single-S tage (On/Off) Boilers - All stage connections on the control board are connected at the {TH} (Thermostat) location on the boiler wiring diagram. Multiple-S tage Boilers - First stage connections on the control board are connected at the {TH} (Thermostat) location on the boiler wiring diagram. - Second (or third, etc.) stage co ...
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Raypak 240692 - page 14
INST ALLA TION VERIFICA TION PROCEDURE REGISTER Before proceeding any further , please verify that the user registration form has been completed and mailed. MECHANICAL INST ALLA TION V erify that the mechanical installation has been completed in accordance with the instructions. OUTDOOR AIR TEMPERA TURE SENSOR V erify that all Outdoor Air T emperat ...
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Raypak 240692 - page 15
CONTROL F AMILIARIZA TION The System is configured using the circuit board jumpers and switches, and the front panel control potentiometers. Open the front cover of the Boiler Control Box for access to the front panel. Remove the front panel to gain access to the jumpers and switches on the Y -Series Electronic Boiler Control circuit board. Refer t ...
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Raypak 240692 - page 16
16 SEQUENCE OF OPERA TION 1. When the reset is enabled, the Y -Series Control continously monitors outdoor temperature using the outdoor temperature sensor . When the outdoor temperature falls below the outdoor cutof f tempersture, the Control becomes active and closes the primary pump relay , energizing the primary system circulating pump. The Con ...
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Raypak 240692 - page 17
17 Panel with Clock & LCD Y -5 Configuration Shown Y–SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option Digital Display Option ...
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Raypak 240692 - page 18
PUMP CALL FOR HEA T CONTROL ON SETTING ERROR SENSOR ERROR INDICA TOR LIGHTS ST AGE INDICA TORS The pump driver and each of the output stages' drivers has its own LED indicator . Each of these LEDs is lit whenever the corresponding output relay is energized. PUMP INDICA T OR The Pump Indicator is illuminated whenever the pump circuit and pump r ...
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Raypak 240692 - page 19
RESET RA TIO The Reset Ratio setting determines how much the T arget T emperature will increase as the outdoor temperature drops. The Reset Ratio is expressed in the following manner: X:Y X - change in outdoor temperature Y - change in T arget T emperature The first number in the ratio refers to the change in outdoor temperature in degrees Fahren- ...
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Raypak 240692 - page 20
RESET RA TIO CHAR T 20 PUMP TURN-OFF DELA Y The Pump T urnoff Delay works in conjunction with the Outdoor Cutoff T emperature. The Pump T urnoff Delay sets the delay between the time when the Outdoor Cutof f T emperature is reached and the time when the pump is turned off . The Pump T urnoff Delay is adjustable from 0 to 10 min. Recommended Initial ...
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Raypak 240692 - page 21
BOILER TURN-ON DELA Y In a multiple boiler system: The Boiler T urn-On Delay sets the time delay before each additional boiler is turned on in response to a call for heat. This delay starts when the preceding boiler is turned on. The Boiler T urn-On Delay range is from 0 to 5 min. Recommended Initial Setting for Boiler T urn-On Delay is 30 sec. ST ...
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Raypak 240692 - page 22
22 MAXIMUM W A TER TEMPERA TURE The Maximum Output T emperature is the system output high limit. This potentiometer sets the maximum value the T arget T emperature is allowed to reach regardless of other operational settings or conditions. The Maximum W ater T emperature range is from 70°F to 235°F . Recommended Initial Setting for Maximum W ater ...
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Raypak 240692 - page 23
CIRCUIT BOARD 23 S5 MANUAL BYP ASS SWITCH S4 MANUAL LEAD/ LAG SELECTOR SWITCH S2 FIRST ST AGE SELECTOR I.D. MAINTENANCE PLUG TEST J2 LAST ST AGE SELECTOR JUMPER S1 SYSTEM TEST S3 MODE SELECTOR ...
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Raypak 240692 - page 24
INTERIOR JUMPER & SWITCHES 24 Fig # 9242 Fig # 9245 Fig # 9246 S-3 J-2 The Last S tage Selector Jumper (J2) is comprised of an eight (8) position jumper block. A shunt bar jumper is placed in the position corresponding to the last active stage or boiler number . See table below for examples of Jumper (J2) settings. The First Stage Selector (Sta ...
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Raypak 240692 - page 25
25 Fig # 9244 Fig # 9243 Fig # 9247 MANUAL LEAD-LAG The Lead-lag Selector Switch (S4) is a ten (10) position rotary switch. Switch positions 0 and 9 are not used. In manual lead-lag selection, the Lead-lag Selector is used to select the lead boiler (stage). This is normally shipped from the factory set at position 1. If auto lead-lag is used, do no ...
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Raypak 240692 - page 26
26 Operational Override Switch Clock Alternate Setpoint Adjustment Digital Display OPTIONAL AL TERNA TE SETPOINT OPERA TION The Optional Alternate Setpoint can be used to establish an independent second set point for setback or temperature boost requirements. TRIPPERS The electro-mechanical timer consists of 84 small switches called "T rippers ...
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Raypak 240692 - page 27
3-C 1-C 2-C 1-S 5-S 4-S 6-S 3-S 5-S 2-S 2-N 1-N 27 CALL OUT 1-C 2-C 3-C 1-S 2-S 3-S 4-S 5-S 6-S 1-N 2-N DESCRIPTION PC Board Standard PC Board w/ Night Set Back Programmed Eprom Programmed Eprom W/ Night Set Back T ransformer Door w/Window Side Mount Bracket Air T emperature Sensor Complete W ater T emperature Sensor Complete Air/W ater T emperatur ...
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Raypak 240692 - page 28
SYSTEM ST AR T -UP SETTINGS SYSTEM SETTING ENTERED ON DA TE: Front panel control potentiometers (knobs) Reset Ratio: ______ Control Band: ______ Default V alue: 1:1 Default V alue: 3°F Pump off Delay: ______ Outdoor Cutoff Deadband: ______ Default V alue: 3 min. Default V alue: 3°F Boiler on Delay: ______ Outdoor Cutoff T emp.: ______ Default V a ...
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Raypak 240692 - page 29
T EM P D e g F 4 05 06 0 7 08 09 0 1 0 0 1 1 0 1 2 0 Re s is t a n c e (K) 26.11 19.90 15.31 11.88 9.30 7.33 5.83 4.66 3.76 T EM P De g F 130 140 150 160 170 180 190 200 210 Re s is t a n c e (K) 3.06 2 .48 2.04 1.69 1.40 1.17 0.98 0.83 0.70 If a ll O ka y , Re p la c e Y -Se rie s Bo i le r Co n t ro l Bo a rd SENS O R RESIS T A NCE A T V A RIO U ...
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Raypak 240692 - page 30
LIMITED WARRANTY B6000, Y-Series, E-4 & Accessories SCOPE OF WARRANTY Raypak, Inc. ("Raypak") warrants to the original owner the Control System to be free from defects in materials and workmanship under normal use and service for the applicable warranty period. In accordance with the terms of this Limited Warranty, RAYPAK will furnish ...
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Raypak 240692 - page 31
Raypak, Inc ., 2151 Eastman A venue, Oxnard, CA 93030 (805) 278-5300 Fax (800) 872-9725 Raypak Canada Limited , 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A. www .raypak.com ...
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